building a sustainable future through innovative technologies
Prof. Nabil NasrDirector, National Center for Remanufacturing & Resource Recovery
Rochester Institute of Technology (RIT)
January 21, 2007
Building a Sustainable Future Through Innovative Technologies
Presentation to:The APEC Market Access Group
building a sustainable future through innovative technologies
building a sustainable future through innovative technologies
NC3R is internationally-recognized as a leading center for applied research in remanufacturing.
NC3R’s mission is to deliver to industry advanced technologies and tools for efficient and cost-effective remanufacturing that have no negative environmental impacts.
Core Areas•Sustainable Design for Remanufacturing•Structural & Material Analysis•Clean Technologies•Intelligent Testing & Diagnostics•Life Cycle Engineering•Condition assessment and non-destructive testing•Enterprise planning for remanufacturing•Logistics & Policy
building a sustainable future through innovative technologies
Examples of CIMS Sponsors
building a sustainable future through innovative technologies
RecognitionAWARDS2006 Most Value National Pollution Prevention Award
2004 New York State Environmental Excellence Award
2004 NCAT Defense Manufacturing Excellence Award
2002 Governor’s Award for Pollution Prevention
building a sustainable future through innovative technologies
Why Remanufacturing?
building a sustainable future through innovative technologies
Net Use of Materials in the U.S.
Source: (Interagency Working Group for Industrial Ecology, Mater ials and Energy Flow, 1998)
building a sustainable future through innovative technologies
The Natural Balance (Post-Industrial Revolution)
building a sustainable future through innovative technologies
Sustainability Defined
EnvironmentalEnvironmental SocialSocial EconomicEconomic
Development that meets the needs of the present Development that meets the needs of the present without compromising the ability of future generations to meet without compromising the ability of future generations to meet
their own needstheir own needs
—— The World Commission on Environmental and Development, 1987The World Commission on Environmental and Development, 1987
building a sustainable future through innovative technologies
Pathway to a Sustainable EconomySome key elements
Sustainable Production•Pollution Prevention•Safe & Healthy Workplaces•Environmental Management Systems•Workforce Engagement
Sustainable Products•Life-cycle Driven Product Design•Healthy Products•Product Labeling•Green Procurement
Closed-Loop, Sustainable Product Systems•Cradle-to-cradle Product Management•Reuse, Remanufacturing Recycling•Zero-to-waste•Transition from Products to Service
Sustainable Economy•Closed-loop, Sustainable Product Systems•Stakeholder Engagement•Renewable Energy•Dematerialized Economy•Green Chemistries•Biobased Products
The Path to a Sustainable Economy
building a sustainable future through innovative technologies
3 Phased Journey to Sustainable Product Systems
Innovation Based Design Design for the Life-Cycle System/integrationProd. & Service Support Strategies
Sustainable Design Tools & MethodsClean ProcessesLife-Cycle DesignKnowledge Base
Life Cycle AnalysisTotal Cost of OwnershipSustainable MaterialsProcess TechnologyEducation & Certification
PHASE 1Sustainable Tools, Methodology, &
Education
PHASE 2Sustainable Design
Processes
PHASE 3Sustainable Product
Systems
DISCOVERY Opportunistic STRATEGIC
Marketing Logistics
Remanufacture Service
Product Disposition
TransportationElements of Product Life‐Cycle
building a sustainable future through innovative technologies
Product Life Cycle
Design
Raw Material Acquisition
Earth & Ecosystem
Processing of Materials
Manu-facturing
Assembly
Use
Service
Upgrade
Retirement
Treatment & Disposal
Emissions
Closed-Loop Product Systems
Disassembly & Inspection
ReuseRemanu-facturing
Material Recycling
building a sustainable future through innovative technologies
Disposition % by Weight
Fuser (Fixing) Assembly, 220V
Fuser (Fixing) Assembly, 220V Feeder Assembly
Laser/Scanner Assembly Cover, Delivery Cover, Delivery
Printer Drive Assembly
Guide, Separation, Upper Cover, Right Roller, Feed Duct, Scanner Spring Tension Hinge, Stopper Spring, TorsionPlate, Roller Holder Roller, Upper, Fuser Guide, Paper Cover, Coupler Cover, Front Plate, Hinge Plate, GuideClaw , Separation Roller, Low er Spring, Torsion Rail, Fuser (Fixing) Cover, Front, Engine Upper Cover Assy Coupler, FixingLever, Delivery Sensing, Fuser Cover, Fixing Roller Guide Feeder Spring, Leaf Cover, Front, Sub
Top Cover Assembly Gear, 42T/99T
Lever, Holding, Right, Fuser Cover, Upper Plate, Terminal Plate, Holder Label, Jam Removal Plate, Grounding Gear, 17T/57T
Lever, Holding, Left, Fuser Cover, Left Sheet, Insulating Plate, Duct, Front Latch Cover, Electrical Gear, 41TCrossmember, Separation Guide Guide, Entrance Block, Shaft Holding, F Mount, Fan Cover, Left, Low er
Open/Close Cover, Assembly Gear, 17T/75T
Spring, Tension Guide, Cable Block, Shaft Holding, R Arm, Lock, Inter Cover, Electrical Stopper. Delivery Gear, 73T
Label, Caution Holder Bushing Spring, Leaf ShutterTray, Face-Dow n Output Tray, Delivery Gear, 27T/30T
Diode Holder Assembly Holder, ThermostatArm, Registration, Paper Sensor Fan Cover, Pow er Sw itch
Cover, Right Door Assembly Gear, 26T/39T
Fixing, Cable, 2 Lever, ControlCover, Static Charge Eliminator Spring, Tension Spring, Compression Cover, Right
Heater, Halogen, 110V Plate, Thermosw itch Frame, Transfer Cable, Laser Cover, Right RearCover, Open/Close, Right
Heater, Halogen, 220V Ring, Grounding Eliminator, Static Charge Cable, Scanner Motor Guide Cover Guide, CoverSurface Temp. Sensor Unit Plate, Grounding Plate, Terminal Cable, BD Spring, Torsion
Stopper, Open/Close
Thermosw itch Plate, Right Cable, Paper Sensor Cable, ILS Panel, Control Front Lever
Gear, 29T Plate, LeftCompression Spring, Front Cover, Cable Control (Display) Panel
Gear, 25T Guide, SeparationCompression Spring, Rear Support, PCB
Panel, Control Front (WX)
Gear, 18TScrew , Stepped, W/Washer, M3 Varistor Spring, Tension Label, Jam Removal
Gear, 14T Frame, Fixing IC, Photo, TLP1230 Spring, Compression Cable AssemblyGear, 48T Guide, Separation Clip, Cable Tray, Face-Up OutputSpring Compression Roller, Delivery Cover, Cable, DC Gear, 20TBearing, Ball Bushing Mount, Control RollerLabel, Caution Gear, 20T Plate, Shield Plate, Guide
Plate, Compression Guide Spring, Torsion Spring, CompressionFixing, Cable, 3 Guide, SeparationLabel, 110V Holder, HeaterLabel, 220V Roller, Delivery, FixingBushingRoller, Cold Offset
building a sustainable future through innovative technologies*National Safety Council
The Gold Mines
building a sustainable future through innovative technologies
What is Remanufacturing?
An industrial process in which non-functional or retired products are restored to like-new conditions.
building a sustainable future through innovative technologies
What is Remanufacturing?A more detailed definition of remanufacturing:
A product is considered remanufactured if:
• Its primary components come from a used product.
• The used product is dismantled to the extent necessary to determine the condition of its components.
• The used product’s components are thoroughly cleaned and made free from rust and corrosion.
• All missing, defective, broken or worn parts are either restored to sound, functionally good condition, or they are replaced with new or remanufactured parts.
• To put the product in sound working condition, such machining, rewinding, refinishing or other operations are performed as necessary.
• The product is reassembled and a determination is made that it will operate similar new product in reliability, life cycle, and operational cost.
building a sustainable future through innovative technologies
Remanufacturing SectorsRemanufacturing Sectors• Defense• Aerospace• Automotive• Medical Equipment• Electrical Apparatus• Compressors• Machinery• Office Furniture/Equipment• Tires• Toner/Inkjet Cartridges• Valves• Consumer electronics
• Other
building a sustainable future through innovative technologies
Remanufactured Products AreasRemanufactured Products AreasOffice Furniture
Plastic Products
Saw Blades
Iron & Steel Forgings
Chrome Plating
Armament Support Equip.
Valves
Steam Turbines
Diesel Engine Components
Farm Equipment
Construction Machinery
Mining Machinery
Oilfield Equipment
Machine Tools:
- Metal Cutting
- Metal Forming
- Welders
Fork Lifts
Power-Driven Handtools
Textile Machinery
Woodworking Machy
Printing Trades Machy
Food Processing Equip.
Shoe Making Machy
Semiconductor Machy
Large Diameter Bearings
Air and Gas Compressors
Indust. Furnaces, Ovens
Mech. Power Transm. Eq.
Computer Parts
Computers & Components
Toner Cartridges
Vending Machines
Refrig. Compressors
Refrig. Components
Hydrostatic Transmissions
Calculating, Accting Mach.
Office Machines
Industrial Machinery
Transformers, Switch Gear
Elec. Motors, Generators
Electronic Controls
TVs & Component Parts
Cellular Telephones
Electron Tubes
Automotive Elec. Equip.
Video Cassettes
Industrial Lasers
Motor Vehicles
Truck and Bus Bodies
Automotive Components
Truck Trailers
Airplanes & Helicopters
Aircraft Engine Components
Aircraft Parts
Railroad Equipment
Radar, Surveillance &
Communication Equip.
Lab Apparatus & Furniture
Industrial Instruments
Fluid Meters & Countg Dev.
Surgical and Med. Apparat.
Medical Sterilizers
X-ray Apparatus and Tubes
Photographic Equipment
Electromedical Equipment
Computer Equip. Repair
Tire Retreading
Remanufacturing is Diverse
building a sustainable future through innovative technologiesUnited Kingdom
building a sustainable future through innovative technologies
building a sustainable future through innovative technologies
Remanufacturing Firms, Industry Sales and Employment*
Sector TotalNum ber of
Firm s
Total Sales(M illions)
TotalEm ploym ent
Autom otive 50,538 $36,546 337,571Com pressors 155 $249 2,878ElectricalApparatus
13,231 $4,633 47,280
M achinery 120 $434 3,155O ffice Furniture 720 $1,663 12,148Tires 1,390 $4,308 27,907Toner C artridges 6,501 $2,475 31,872Valves 410 $589 4,577O ther 250 $2,009 14,372
Total 73,315 $52,906 481,760*”The Remanufacturing Industry: Hidden Giant”, Robert Lund
building a sustainable future through innovative technologies
Industry Vision
building a sustainable future through innovative technologies
The Remanufacturing Industries Council
• Recycling Industries– $ 7.2 Billion– 103,000 Jobs
• Remanufacturing Industries– 73,000 Companies– $53+ billion in sales– 481,760 Jobs
building a sustainable future through innovative technologies
Remanufacturing Technology Challenges
building a sustainable future through innovative technologies
Health Monitoring Development ProcessExpanded RCM
Feature Design
Fault Progression
Sensor Placement
Testing:- Seeded fault- Transitional
Feature Design
Fault Progression
Sensor Placement
Feature Design
Fault Progression
Sensor Placement
Feature Design
Fault Progression
Sensor Placement
Testing:- Seeded fault- Transitional
Prognostic Engine
Diagnostic Engine
Optional
Diagnostic -Inference Model
(Tests and Observables)
Expanded FMECA
FMECA Analysis
Fault / Damage Indicators
Usage Indicators
Expanded FMECA
FMECA Analysis
Fault / Damage Indicators
Usage Indicators
Components
Expanded RCM
RCM Functional Analysis
System Performance & Condition Indicators
System Context Indicators
System
Signature Analysis & Feature
Identification
Fault Detection and Isolation
Analysis
Feed
back
loop
s
Diagnostic Cost / Benefit Assessment
PARETO Analysis
Prognostic ModelOptional
Sensor Set
Signal Proc
Feedback
Feedback
DRV_SGTo Workspace12
DRV_theo_dischargeTo Workspace11
PmfbTo Workspace10
DRV_max_closeTo Workspace1
DRV_max_openTo Workspace
TheoreticalDischarge
Spool Stroke
SG60SG60
f(u)Pilot Window Flow f(u)
Pilot Window Areau[1] / 0.04
Pilot Spool Stroke
PWFl
PWArea
f(u)Orifice Area
61.33Nominal SP Offset
MuxMux
MuxMux
Mux
MuxMux
Mux
Mux
Mux
Mux
f(u)Leakage
f(u)Gain Damping
Orifice dp0.006
Gain DampingOrifice Dia
0.0647DRV min Area
DRV dp
f(u)DRV Valve
Opening Area
DRV VPdp
DRV SetpointOffset
f(u)DRV SP Offset
u[5] - u[1]DRV Pressure
Drop
DRV PilotLeakage Flow
f(u)DRV Outlet Temp
DRV Outlet Press
DRV OutletTemperature
f(u)DRV Max Open
f(u)DRV Max Close
f(u)DRV Heat Rejection
f(u)DRV Discharge
Pressure
CEXCEX
f(u)Average SG
f(u)Average
Specific Heat
5EFP Tout
4EFP Outlet Press
3TPF
2A/C Boost Press
1Manifold Press
DRV_SGTo Workspace12
DRV_theo_dischargeTo Workspace11
PmfbTo Workspace10
DRV_max_closeTo Workspace1
DRV_max_openTo Workspace
TheoreticalDischarge
Spool Stroke
SG60SG60
f(u)Pilot Window Flow f(u)
Pilot Window Areau[1] / 0.04
Pilot Spool Stroke
PWFl
PWArea
f(u)Orifice Area
61.33Nominal SP Offset
MuxMux
MuxMux
Mux
MuxMux
Mux
Mux
Mux
Mux
f(u)Leakage
f(u)Gain Damping
Orifice dp0.006
Gain DampingOrifice Dia
0.0647DRV min Area
DRV dp
f(u)DRV Valve
Opening Area
DRV VPdp
DRV SetpointOffset
f(u)DRV SP Offset
u[5] - u[1]DRV Pressure
Drop
DRV PilotLeakage Flow
f(u)DRV Outlet Temp
DRV Outlet Press
DRV OutletTemperature
f(u)DRV Max Open
f(u)DRV Max Close
f(u)DRV Heat Rejection
f(u)DRV Discharge
Pressure
CEXCEX
f(u)Average SG
f(u)Average
DRV_SGTo Workspace12
DRV_theo_dischargeTo Workspace11
PmfbTo Workspace10
DRV_max_closeTo Workspace1
DRV_max_openTo Workspace
TheoreticalDischarge
Spool Stroke
SG60SG60
f(u)Pilot Window Flow f(u)
Pilot Window Areau[1] / 0.04
Pilot Spool Stroke
PWFl
PWArea
f(u)Orifice Area
61.33Nominal SP Offset
MuxMux
MuxMux
Mux
MuxMux
Mux
Mux
Mux
Mux
f(u)Leakage
f(u)Gain Damping
Orifice dp0.006
Gain DampingOrifice Dia
0.0647DRV min Area
DRV dp
f(u)DRV Valve
Opening Area
DRV VPdp
DRV SetpointOffset
f(u)DRV SP Offset
u[5] - u[1]DRV Pressure
Drop
DRV PilotLeakage Flow
f(u)DRV Outlet Temp
DRV Outlet Press
DRV OutletTemperature
f(u)DRV Max Open
f(u)DRV Max Close
f(u)DRV Heat Rejection
f(u)DRV Discharge
Pressure
CEXCEX
f(u)Average SG
f(u)Average
Specific Heat
5EFP Tout
4EFP Outlet Press
3TPF
2A/C Boost Press
1Manifold Press
Specific Heat
5EFP Tout
4EFP Outlet Press
3TPF
2A/C Boost Press
1Manifold Press
DRV_SGTo Workspace12
DRV_theo_dischargeTo Workspace11
PmfbTo Workspace10
DRV_max_closeTo Workspace1
DRV_max_openTo Workspace
TheoreticalDischarge
Spool Stroke
SG60SG60
f(u)Pilot Window Flow f(u)
Pilot Window Areau[1] / 0.04
Pilot Spool Stroke
PWFl
PWArea
f(u)Orifice Area
61.33Nominal SP Offset
MuxMux
MuxMux
Mux
MuxMux
Mux
Mux
Mux
Mux
f(u)Leakage
f(u)Gain Damping
Orifice dp0.006
Gain DampingOrifice Dia
0.0647DRV min Area
DRV dp
f(u)DRV Valve
Opening Area
DRV VPdp
DRV SetpointOffset
f(u)DRV SP Offset
u[5] - u[1]DRV Pressure
Drop
DRV PilotLeakage Flow
f(u)DRV Outlet Temp
DRV Outlet Press
DRV OutletTemperature
f(u)DRV Max Open
f(u)DRV Max Close
f(u)DRV Heat Rejection
f(u)DRV Discharge
Pressure
CEXCEX
f(u)Average SG
f(u)Average
Specific Heat
5EFP Tout
4EFP Outlet Press
3TPF
2A/C Boost Press
1Manifold Press
DRV_SGTo Workspace12
DRV_theo_dischargeTo Workspace11
PmfbTo Workspace10
DRV_max_closeTo Workspace1
DRV_max_openTo Workspace
TheoreticalDischarge
Spool Stroke
SG60SG60
f(u)Pilot Window Flow f(u)
Pilot Window Areau[1] / 0.04
Pilot Spool Stroke
PWFl
PWArea
f(u)Orifice Area
61.33Nominal SP Offset
MuxMux
MuxMux
Mux
MuxMux
Mux
Mux
Mux
Mux
f(u)Leakage
f(u)Gain Damping
Orifice dp0.006
Gain DampingOrifice Dia
0.0647DRV min Area
DRV dp
f(u)DRV Valve
Opening Area
DRV VPdp
DRV SetpointOffset
f(u)DRV SP Offset
u[5] - u[1]DRV Pressure
Drop
DRV PilotLeakage Flow
f(u)DRV Outlet Temp
DRV Outlet Press
DRV OutletTemperature
f(u)DRV Max Open
f(u)DRV Max Close
f(u)DRV Heat Rejection
f(u)DRV Discharge
Pressure
CEXCEX
f(u)Average SG
f(u)Average
DRV_SGTo Workspace12
DRV_theo_dischargeTo Workspace11
PmfbTo Workspace10
DRV_max_closeTo Workspace1
DRV_max_openTo Workspace
TheoreticalDischarge
Spool Stroke
SG60SG60
f(u)Pilot Window Flow f(u)
Pilot Window Areau[1] / 0.04
Pilot Spool Stroke
PWFl
PWArea
f(u)Orifice Area
61.33Nominal SP Offset
MuxMux
MuxMux
Mux
MuxMux
Mux
Mux
Mux
Mux
f(u)Leakage
f(u)Gain Damping
Orifice dp0.006
Gain DampingOrifice Dia
0.0647DRV min Area
DRV dp
f(u)DRV Valve
Opening Area
DRV VPdp
DRV SetpointOffset
f(u)DRV SP Offset
u[5] - u[1]DRV Pressure
Drop
DRV PilotLeakage Flow
f(u)DRV Outlet Temp
DRV Outlet Press
DRV OutletTemperature
f(u)DRV Max Open
f(u)DRV Max Close
f(u)DRV Heat Rejection
f(u)DRV Discharge
Pressure
CEXCEX
f(u)Average SG
f(u)Average
Specific Heat
5EFP Tout
4EFP Outlet Press
3TPF
2A/C Boost Press
1Manifold Press
Specific Heat
5EFP Tout
4EFP Outlet Press
3TPF
2A/C Boost Press
1Manifold Press
Phys
ical
/ Si
mul
atio
n M
odel
Operating Modes for detection
Fault Progression Pattern
Historical Knowledge (maint/failure histories)
System Operating Modes
building a sustainable future through innovative technologies
Remanufacturing in mainstream retail markets
building a sustainable future through innovative technologies
OPC Drum Life-Cycle Analyzer
Solution: OPC Drum Life-Cycle Analyzerthe OPC Drum Life-Cycle Analyzer detects how many times the drum can be reused
15 million drums represent used annually in the US
tons of materials are diverted from landfills
building a sustainable future through innovative technologies
Wiper Blade Edge AnalyzerProblem
2.6M pounds of sheet metal from unrecycled wiper blades end up in landfills annually
Solution: Wiper Blade Edge AnalyzerOver 1,000,000 wiper blades successfully reused in the global remanufacturing of toner print cartridgesSub-licensed to 8 remanufacturing companiesDiverted over 260 ton of steel and plastic from landfill
Awarded2004 NYS Environmental Excellence Award
building a sustainable future through innovative technologies
Office Furniture RemanufacturingSponsor:Davies Office Refurbishing, Inc.
FindingsCosts 25–75% less than new furniture
Natural resources, such as wood and aluminum, as well as steel, plastics, and fiber, may be reused over and over to the fullest extent possible
Conserves labor and manufacturing energy
Reduces global warming, acid rain, photochemical smog, and other forms of air pollution
building a sustainable future through innovative technologies
Examples of Remanufacturing
building a sustainable future through innovative technologies
Case Study: Office Furniture
Fabric is cleaned; desk tops are re-covered; dents in metal are hammered out
Small parts are replaced; all movable parts are tested
Furniture style is updated
Avoids disposal costs - $93 million in U.S. annually
30 to 50% cost savings for businesses
Conserves one tractor trailer worth of material for every 40 cubicles remanufactured
building a sustainable future through innovative technologies
Case Study: PhotocopiersXerox Document Center 265*
designed to include easily removable subassemblies and more durable parts
Xerox takes back the used copiers.
80% of the parts are remanufacturable
designed to be upgraded
Remanufacturing diverted 4 million cubic feet of material from landfill in one year company-wide.
Xerox saves several hundred million dollars per year by designing parts for remanufacture and recycling.
*Environment Health and Safety Progress Report. Xerox Corporation. Available through: www.xerox.com
building a sustainable future through innovative technologies